Bonding of particles on composite structures

Abstract

A vehicle component includes a composite laminate. The vehicle component also includes a substrate coupled to an outer surface of the composite laminate. The vehicle component also includes a coating. The coating is thermally applied to the substrate. The substrate facilitates bonding between the thermal coat coating and the substrate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 431,452, filed on December 9, 2022, the entire contents of which are hereby incorporated by reference. Background Art

[0003] Mechanical structures or components, such as those used in aircraft or automobiles, are often coated to protect them, including from the effects of erosion and to extend their service life. These coatings typically utilize a variety of material combinations tailored to the specific needs of the component or application, exhibiting good corrosion or erosion resistance, and are applied using a variety of known processes. Thermal spraying is one such coating process, in which the protective material is exposed to high heat and high velocity as it is sprayed onto the component. The high heat melts the material in transit, which then impacts the component surface and solidifies, forming a protective layer.

[0004] Those skilled in the art will appreciate that the bond strength (or adhesion) of a protective coating to a component can vary significantly depending on the material properties of the coating and the component. Applying certain erosion and corrosion protection coatings with desirable properties may result in a weak bond to a component. Due to this weak bond, the protective coating may prematurely fall off a component in service.

[0005] The present invention therefore seeks to promote the bonding of particles, such as erosion control materials, applied to composite parts. Summary of the Invention

[0006] In a first exemplary embodiment, a vehicle component is provided. The vehicle component includes a composite laminate, a substrate coupled to an outer surface of the composite laminate, and a coating. The coating is thermally applied to the substrate. The substrate facilitates bonding between the thermally applied coating and the substrate.

[0007] In various embodiments, the substrate is a composite material comprising a plurality of particles comprising at least one particulate material, wherein the plurality of particles promotes bonding between the thermal coating and the substrate. The composite material also includes a resin and fibers impregnated with the resin.

[0008] In various embodiments, the fibers of the substrate are coated with a plurality of particles.

[0009] In various embodiments, a plurality of particles are disposed within the resin of the substrate.

[0010] In various embodiments, the fibers impregnated with the resin are first fibers, and the composite laminate includes second fibers different from the first fibers.

[0011] In various embodiments, a substrate includes a resin and a plurality of particles. The plurality of particles includes at least one particulate material, wherein the plurality of particles promotes bonding between the thermally coated coating and the substrate.

[0012] In various embodiments, the plurality of particles are randomly disposed throughout the resin.

[0013] In various embodiments, at least 50% of the plurality of particles are disposed on the surface of the substrate comprising the thermally coated coating.

[0014] In various embodiments, the resin is a thermoplastic resin.

[0015] In various embodiments, the resin is a thermosetting resin.

[0016] In various embodiments, the type of resin used in the composite laminate is the same as the resin of the substrate.

[0017] In various embodiments, the substrate is co-cured with the composite laminate and forms an outer ply along a portion of the composite laminate.

[0018] In various embodiments, the plurality of particles includes a first particulate material and a second particulate material different from the first particulate material.

[0019] In various embodiments, the particulate material of the coating is the same as at least one particulate material of the plurality of particles of the substrate.

[0020] In various embodiments, the coating is thermally coupled to at least one particle of the plurality of particles of the substrate.

[0021] In various embodiments, the vehicle component is a rotor blade.

[0022] In various embodiments, the coating is thermally applied between 0% and 25% chord length from the leading edge of the rotor blade.

[0023] In a second exemplary embodiment, a method for bonding a coating to a composite laminate structure is provided. The method includes preparing a substrate for bonding to an uncured composite laminate. The substrate includes a resin material and a plurality of particles, wherein the plurality of particles form anchor points for deposition of the coating. The method also includes co-curing the substrate and the composite laminate such that the substrate is disposed on a portion of an outer surface of the composite laminate. The method also includes determining, for the coating, at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating. The method further includes depositing the coating onto the surface of the substrate using thermal spraying such that the at least one deposition material couples with the at least one particulate material of the substrate.

[0024] In various embodiments, preparing the substrate for incorporation into the uncured composite laminate further comprises determining the amount and type of at least one of a resin material, a fiber material, and at least one particulate material. When determining the resin material, the determination is based on the material properties of the resin material used in the composite laminate; when determining the at least one particulate material, the determination is based on the bonding properties of the at least one particulate material with the at least one deposition material used for the coating.

[0025] In various embodiments, preparing a substrate for bonding to an uncured composite laminate further comprises randomly distributing a plurality of particles throughout a resin to form a particle-impregnated resin; impregnating a fibrous material with the particle-impregnated resin to form a particle-impregnated ply; and joining a surface of the particle-impregnated ply to a surface of the uncured composite laminate.

[0026] In various embodiments, the substrate further comprises a plurality of fibers coated with a plurality of particles to form particle-coated fibers.

[0027] In various embodiments, the particle-coated fibers are impregnated with a resin material.

[0028] In various embodiments, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are coated onto the fibers.

[0029] In various embodiments, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are randomly distributed throughout the resin.

[0030] In various embodiments, the composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate includes thermally spraying the coating at between 0% and 25% chord length from a leading edge of the rotor blade.

[0031] In a third exemplary embodiment, a method for bonding a coating to a composite laminate structure is provided. The method includes preparing a substrate for bonding to a cured composite laminate. The substrate includes a resin material and a plurality of particles, wherein the plurality of particles form anchor points for deposition of the coating. The method also includes applying the prepared substrate to an outer surface of the cured composite laminate. The method also includes curing the prepared substrate onto the outer surface of the cured composite laminate. The method further includes determining at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating for the coating. The method also includes depositing the coating onto the surface of the substrate using thermal spraying such that the at least one deposition material couples with the at least one particulate material of the substrate.

[0032] In various embodiments, preparing the substrate for incorporation into the cured composite laminate further comprises determining an amount and type of at least one of a resin material, a fiber material, and at least one particulate material, wherein when determining the at least one particulate material, the determination is based on the bonding properties of the at least one particulate material with the at least one deposition material for the coating.

[0033] In various embodiments, preparing a substrate for bonding to a cured composite laminate further includes randomly distributing a plurality of particles throughout a resin to form a particle-impregnated resin; impregnating a fibrous material with the particle-impregnated resin to form a particle-impregnated ply; and joining a surface of the particle-impregnated ply to a surface of the cured composite laminate.

[0034] In various embodiments, the substrate further comprises a plurality of fibers coated with a plurality of particles to form particle-coated fibers.

[0035] In various embodiments, the particle-coated fibers are impregnated with a resin material.

[0036] In various embodiments, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are coated onto the fibers.

[0037] In various embodiments, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are randomly distributed throughout the resin.

[0038] In various embodiments, the composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate includes thermally spraying the coating at between 0% and 25% chord length from a leading edge of the rotor blade.

[0039] These and other aspects, advantages and alternatives will become apparent to those skilled in the art by reading the following detailed description, with reference where appropriate to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is a perspective view of a rotor according to an exemplary embodiment of the present invention.

[0041] Figure 2 is a cross-sectional view of a vehicle component including a coated fiber layer according to an exemplary embodiment of the present invention.

[0042] Figure 3 is a cross-sectional view of a vehicle component including a particle-impregnated prepreg according to an exemplary embodiment of the present invention.

[0043] Figure 4A is a cross-sectional view of a vehicle component including a particle embedding surface according to an exemplary embodiment of the present invention.

[0044] Figures 4B to 4C yes Figure 4A An exploded cross-sectional view of an exemplary embodiment of FIG.

[0045] Figure 5 is a block diagram illustrating a method of bonding a coating to a composite laminate structure according to an exemplary embodiment of the present invention.

[0046] Figure 6 is a block diagram illustrating another method of bonding a coating to a composite laminate structure according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION

[0047] Disclosed herein are examples of various features and functions of the disclosed apparatus, processes, and methods, described with reference to the accompanying drawings. The drawings are not necessarily drawn to scale, and the dimensions of various elements may be distorted for clarity. It should be understood that various aspects of the disclosed apparatus, processes, and methods may be arranged and combined in a variety of different configurations, all of which are contemplated herein. The present disclosure generally relates to promoting adhesion and bond strength of particles to composite laminates.

[0048] The present application relates to processes, techniques and materials for promoting the adhesion of particles or materials (e.g., erosion-resistant materials) to structures (such as the leading edge of a rotor blade). In some embodiments, the rotor blade can be part of a vehicle. In some embodiments, the vehicle can be a vertical take-off and landing (VTOL) vehicle that can hover, take off and / or land with or without propellers. It should be understood that in other embodiments, the vehicle can be any other type of vehicle that can utilize the advantages of the present invention, such as a ground vehicle (i.e., a car), a sea vehicle (such as a ship), or an aircraft (such as an aerial, floating, soaring, hovering, ascending, an aeroplane, an airplane (airplane, plane), a spacecraft, a helicopter, an airship, or an unmanned vehicle or drone).

[0049] In some embodiments, the vehicle may include one or more propellers for driving the vehicle. The one or more propellers may each include a plurality of rotor blades, such as those described below with respect to Figure 1 The rotor blade 100 is described. The rotor blade 100 may include a composite laminate and may or may not have a cross-sectional airfoil shape. Each propeller may be configured, for example, as a tiltrotor, a liftrotor, or any other type of rotorcraft. In other embodiments, the vehicle may include one or more turbine engines, one or more tires, one or more ski structures, etc., instead of one or more propellers for driving the vehicle.

[0050] Figure 1An example rotor blade 100 is shown to which materials of the present application may be applied. The rotor blade 100 may include a root 104 attached to a rotor hub 102, a tip 106 opposite the root 104, a leading edge 108, and a trailing edge 110 opposite the leading edge 108. The rotor blade 100 may rotate clockwise or counterclockwise about the rotor hub 102. The rotor blade 100 may include any suitable material, such as a composite laminate, and may have a cross-sectional thickness that varies from the leading edge 108 to the trailing edge 110 and / or a thickness that varies along its length from the root 104 to the tip 106.

[0051] Figure 2 is a cross-sectional view of a vehicle component 200 comprising multiple layers according to an exemplary embodiment of the present invention. As shown, the vehicle component 200 may include a composite laminate 230, a coated fiber layer 220, and a coating 210. In some embodiments, the vehicle component may be a rotor blade, such as Figure 1 The rotor blade 100 is shown. However, it should be understood that the vehicle component 200 can be other structural or non-structural components. For example, the vehicle component 200 can be a fairing, a flap, an elevator, a wing skin, a fuselage member, etc.

[0052] Composite laminate 230 in the exemplary embodiment is a structural component of the rotor blade and is designed to carry the loads of the entire rotor blade. Composite laminate 230 may have an airfoil cross-sectional shape and serve as a lift- or thrust-generating surface. In other examples, composite laminate 230 may have other cross-sectional shapes, such as an aerodynamic component of a nacelle or aircraft fuselage.

[0053] Those skilled in the art will recognize that the composite laminate 230 can include a variety of fiber types (aramid, carbon, glass, etc.), weave or non-weave patterns (chopped, unidirectional, plain, 2×2 twill, 4×4 twill, 5-piece harness, 8-piece harness, etc.), matrices (metal matrices; thermoplastic and thermoset polymer matrices, such as epoxy resins), etc. The composite laminate 230 can also vary in the number of plies used, the specific ratio of fiber to matrix, and the orientation of the respective plies.

[0054] In the exemplary embodiment shown, the coating fiber layer 220 conforms to the outer surface of the composite laminate 230. The coating fiber layer 220 serves as at least an attachment point, a bonding point, or an anchoring point for the coating layer 210. In some examples, the coating layer 210 can be mechanically bonded, physically bonded, and / or chemically bonded to the coating fiber layer 220. The coating fiber layer 220 can conform to all or part of the shape and design of the composite laminate 230. Although Figure 2The coated fiber layer 220 is shown positioned above the composite laminate 230, but it should be understood that the coated fiber layer 220 can be positioned on any surface of the composite laminate 230. For example, in a rotor blade having a cross-sectional airfoil shape, the coated fiber layer 220 can be positioned on the leading edge, the trailing edge, the upper camber (upper surface), and / or the lower camber (lower surface). The coated fiber layer 220 can cover the entire outer surface area of ​​the composite laminate 230, or it can cover only a portion of the outer surface area of ​​the composite laminate 230. For example, the amount of surface area of ​​the composite laminate 230 covered by the coated fiber layer 220 can be within any range known to those skilled in the art, as long as it is suitable for the application. Furthermore, the coated fiber layer 220 can be positioned along selected portions of the composite laminate 230. For example, in a composite laminate rotor blade, the coated fiber layer 220 can cover the leading edge and the first 25% of the chord length of the upper surface. The coated fiber layer 220 may span the longitudinal length of the composite laminate 230 , such as from the root to the tip of the rotor blade. However, in other examples, the coated fiber layer 220 may be positioned along only a portion of the longitudinal length of the composite laminate 230 .

[0055] In some embodiments, the coated fiber layer 220 can be cured as a surface ply or series of plies to the composite laminate 230 during the initial layup. In such embodiments, during the manufacture of the vehicle component 200, the composite laminate 230 will include a surface ply or series of plies of the coated fiber layer 220: the entire ply stack can then be cured so that the surface ply of the stack is at least the coated fiber layer 220. Those skilled in the art will appreciate the various methods that can be used to manufacture composite layups for structural and non-structural composite parts.

[0056] However, in other embodiments, the composite laminate 230 can be modified by bonding the coated fiber layer 220 to the surface. The resin / matrix used to bond the coated fiber layer 220 to the composite laminate 230 can be the same or similar to the resin / matrix used in the composite laminate 230. The resin / matrix used to bond the coated fiber layer 220 to the composite laminate can also include particles, such as metal and / or ceramic particles, to better allow for adhesion of the coating 210. In some embodiments, the coated fiber layer 220 can be cured onto the composite laminate 230 at room temperature and standard atmospheric pressure. In other embodiments, curing may involve an autoclave, a heating blanket, and / or a vacuum bag.

[0057] Once cured onto the composite laminate 230, the surface of the coated fiber layer 220 may be prepared to further promote adhesion of the coating 210. In some embodiments, the surface of the coated fiber layer 220 does not require any treatment prior to application of the coating 210. The determination of the surface treatment employed in preparing the fiber layer 220 for coating may vary based on the coating 210 being applied.

[0058] The coated fiber layer 220 can be made of any type of suitable fiber and weave pattern and can incorporate any type of suitable metal, ceramic, or cermet coating. In some embodiments, the coated fiber layer 220 can be a continuously coated fiber layer; however, it can also be individually coated fibers or tows. In some embodiments, the coated fiber layer 220 can be a plurality of fibers arranged in a random or indistinguishable orientation that are subsequently coated with a continuous metal layer, such as VeeloVEIL. TM . While in other embodiments, the fiber orientation may not be random and / or the fibers may be coated prior to forming the woven fabric. For example, and without in any way limiting the scope of the invention, the coated fiber layer 220 may include randomly arranged carbon fiber bundles that are subsequently coated in a metal or metal alloy. The coated fiber layer 220 may act as a non-structural unit, or it may be structural and designed to transfer loads in conjunction with the composite laminate 230. The material selected for the coated fiber layer 220 may be based at least in part on its ability to bond with the coating 210. In some embodiments, the selected coated fiber layer 220 may be based at least in part on other properties, such as lightning strike protection.

[0059] Although in the exemplary embodiment shown, coating 210 is a metallic erosion resistant coating, other types of coatings, such as corrosion resistant coatings, are also contemplated. Coating 210 can be made of a single metal or metal alloy, multiple metals or metal alloys, a single ceramic material, a combination of ceramic materials, and / or a combination of one or more ceramic materials with one or more metals (including metal alloys). For example, coating 210 can include aluminum, aluminum alloys, tungsten, tungsten alloys, cobalt, cobalt alloys, nickel, nickel alloys, chromium, chromium alloys, molybdenum, molybdenum alloys, iron, iron alloys, zinc, zinc alloys, combinations of metals and / or metal alloys, carbides combined with metals and / or metal alloys, nickel-chromium-aluminum, chromium oxide, aluminum oxide-titania, aluminum oxide, chromium carbide, tungsten carbide, tungsten carbide-nickel, etc. One of ordinary skill in the art will recognize the various types of coatings that can be used or considered.

[0060] The coating 210 can have a constant thickness along a cross-section of the vehicle component 200, or its thickness can vary along the cross-section of the vehicle component 200. Furthermore, the coating 210 can have a constant thickness, or its thickness can vary along the longitudinal length (such as the length spanning from the root of a rotor blade to the tip of a rotor blade) of the vehicle component 200. In some embodiments, the thickness of the coating 210 on the vehicle component 200 can be in a range between 10-100 μm, 100-500 μm, 500-1,000 μm, or 1,000-5,000 μm.

[0061] Although the coating 210 is applied using a thermal spray process as shown in the exemplary embodiment, other coating methods and processes may also be used. The thermal spraying of the coating 210 may be performed using high velocity oxygen fuel spray (HVOF), high velocity air fuel spray (HVAF), air plasma spray, combustion wire and powder spray, twin wire arc spray, spray and fuse hardening, cold gas dynamic spray (CGDS), etc.

[0062] Thermal spraying temperatures can vary depending on the coating material being sprayed and the spraying process. For example, the HVAF process can spray at temperatures of approximately 1900-1950 degrees Celsius, while the HVOF process can spray at much higher temperatures, such as approximately 1000 degrees Celsius higher than the HVAF process. Furthermore, the process temperature, particle velocity, and particle material used can affect the coating's bond strength (ability to bond) and crack resistance.

[0063] Spraying at temperatures closer to the melting point of the particulate material rather than its boiling point can reduce cracking of the coating and can further mitigate negative structural effects in the sprayed component caused by higher spray temperatures. Structural components (e.g., composites) coated by thermal spray processes can be susceptible to structural damage above certain spray temperature ranges, so using lower spray temperatures when coating composite components can be beneficial.

[0064] After coating 210 is applied to coated fiber layer 220 of vehicle component 200, surface preparation may be performed. For example, coating 210 may need to be polished or honed to increase surface smoothness and remove burrs or other rough features present on the surface. However, in some embodiments, only a portion of surface coating 210 may need to be polished or honed. For example, on a rotor blade, the coating on the leading edge portion and 0-25% of the chord length may be polished or honed to allow laminar flow, while coating 210 above 25% of the chord length may not be polished or may be further honed to promote turbulent flow by tripping the boundary layer.

[0065] Figure 3 FIG2 is a cross-sectional view of a vehicle component 300 including a particle-impregnated prepreg according to an exemplary embodiment of the present invention. The vehicle component 300 in the exemplary embodiment can be any structural or non-structural composite laminate-based component, such as a rotor blade, such as rotor blade 100. As shown, the vehicle component 300 can include a composite laminate 330 having a particle-impregnated prepreg layer 320 and a coating 310.

[0066] As shown in the exemplary embodiment, particle-impregnated prepreg layers 320 are mated to the outer surface of the composite laminate 330. The particle-impregnated prepreg layers 320 can serve as attachment points, bonding points, or anchoring points for the coating 310. The particle-impregnated prepreg layers 320 can promote adhesion of the coating 310, thereby mitigating or preventing premature bond failure of the coating 310 on the vehicle component 300.

[0067] The particle-impregnated prepreg layer 320 may include a sheet of fibers and a resin matrix, wherein the fibers are pre-impregnated with the resin matrix. The fibers in the particle-impregnated prepreg layer 320 may be any suitable material, such as aramid fibers, carbon fibers, glass, etc. The fiber weave of the particle-impregnated prepreg layer 320 may be any suitable weave. For example, the prepreg fiber design may be unidirectional, plain weave, 2×2 twill, 4×4 twill, 5-hedged weave, 8-hedged weave, etc. However, in some embodiments, the fibers of the particle-impregnated prepreg layer 320 may not include a weave pattern and / or a discernible fiber orientation, and may be dispersed in a random orientation.

[0068] Furthermore, the resin matrix can also have any suitable composition, type, or structure; for example, the resin can be a metal matrix or a thermoplastic / thermosetting polymer matrix, such as an epoxy resin. The resin / matrix of the particle-impregnated prepreg layer 320 can also be impregnated or doped with particles. The particles can be metallic, ceramic, or cermet. The particles can comprise various alloys, sizes, shapes, and structures, with the selection being based at least in part on the adhesion / bonding strength capabilities with the coating 310. The distribution and concentration of the particles can be further optimized based on the adhesion / bonding strength capabilities with the coating 310.

[0069] Coating 310 may have the same properties as described above for coating 210. In some embodiments, the particles of coating 310 may be of the same or similar material as at least one material applied in coating 210. The amount of particles included in the resin / matrix of particle-impregnated prepreg layer 320 may vary depending on design requirements.

[0070] In some embodiments, the fibers of the particle-impregnated prepreg layer 320 may themselves include a metal and / or particle coating. For example, in addition to a metal, ceramic, or cermet-impregnated resin / matrix, the particle-impregnated prepreg layer 320 may also utilize metal-coated fibers. In other examples, the particle-impregnated prepreg layer 320 may utilize an unimpregnated resin / matrix with metal-coated fibers. However, in other embodiments, the resin / matrix may be impregnated or doped with particles, while the fibers may not be coated with particles. In further embodiments, however, the particles of the particle-impregnated prepreg layer 320 may be distributed and / or pressed onto a surface prior to curing; for example, a surface that is subsequently coated with the coating 310. Thus, the particles may be present both as a coating on the fibers and dispersed in the matrix, present only as a coating on the fibers, dispersed only within the matrix, or dispersed along a surface.

[0071] Once the particle-impregnated prepreg layer 320 has been cured, the distributed and / or pressed surface particles may serve as attachment points or bonding points for the coating layer 310 and may promote additional bond strength between the coating layer 310 and the particle-impregnated prepreg layer 320. The particles selected for the surface distribution may be similar to the particles described with respect to other embodiments disclosed herein.

[0072] As previously described, the particle-impregnated prepreg layer 320 can serve as an adhesion, anchoring, and / or bonding promoter for the coating 310; the enhanced adhesion can allow for the use of reduced temperatures and / or speeds during the application (e.g., thermal spraying) of the coating 310. The particle-impregnated prepreg layer 320 can include a single ply or multiple plies. The thickness of the particle-impregnated prepreg layer 320 depends, at least in part, on the number of plies used and the corresponding thickness of each ply.

[0073] The surface preparation of the vehicle component 300 can be performed before and / or after any step of the process. For example, before applying the particle-impregnated prepreg layer 320, the composite laminate 330 can be surface treated, such as by grinding, to increase the bonding strength and adhesion of the particle-impregnated prepreg layer 320. Similarly, before applying the coating layer 310, the particle-impregnated prepreg layer 320 can be surface treated, such as by grinding, to promote adhesion and increase the bonding strength of the coating layer 310.

[0074] Abrading can be performed using techniques known to those skilled in the art. For example, emery cloth or sandblasting can be used. Abrading the particle-impregnated prepreg layer 320 can create more attachment points for the particles in the coating 310 to anchor or attach, which may require lower coating temperatures and speeds than would otherwise be required. This can protect the structural properties of the composite laminate 330 from being damaged during coating. The techniques contemplated in these paragraphs for vehicle component 300 are equally applicable to vehicle component 200.

[0075] In some embodiments, the particle impregnated prepreg layers 320 may also be included as a structural feature and help transfer loads throughout the vehicle component 300, while in other embodiments, the particle impregnated prepreg layers 320 do not significantly contribute to the overall load-bearing capacity.

[0076] Figure 4A FIG is a cross-sectional view of a vehicle component 400 including a particle embedded surface according to an exemplary embodiment of the present invention. As shown, the vehicle component 400 may include a composite laminate 430 having a particle embedded surface 420 and a coating 410 disposed on an outer surface of the particle embedded surface 420. Figure 4A The particle embedding surface 420 is shown as being located above the composite laminate 430 , but it should be understood that the particle embedding surface 420 may be located on any surface of the composite laminate 430 .

[0077] For example, in a rotor blade having a cross-sectional airfoil shape, the particle embedding surface 420 can be located on the leading edge, the trailing edge, the upper camber (upper surface), and / or the lower camber (lower surface). The particle embedding surface 420 can cover the entire outer surface area of ​​the composite laminate 430, or can cover only a portion of the outer surface area of ​​the composite laminate 430. For example, the amount of surface area of ​​the composite laminate 430 covered by the particle embedding surface 420 can be in a range between 1-20%, 20-50%, 50-75%, or 75-100% of the total surface area. Furthermore, the particle embedding surface 420 can be positioned along a selected portion of the composite laminate 430. For example, in a composite laminate rotor blade, the particle embedding surface 420 can cover the leading edge and the first 25% of the chord length of the upper surface.

[0078] The particle embedding surface 420 may span the longitudinal length of the composite laminate 430, for example, from the root to the tip of the rotor blade. However, in other examples, the particle embedding surface 420 may be located only along a portion of the longitudinal length of the composite laminate 430. The composite laminate 430 may include the same or similar structure, materials, and other aspects as the composite laminates 230 and / or 330 described above. The curing of the particle embedding surface 420 may be performed in the same manner as described above with respect to Figure 2 and Figure 3 The same or similar manner as described above may be used, or the same or similar manner as described above may be used, or may be used by techniques known now or in the future to those skilled in the art.

[0079] Figure 4B and Figure 4C Shown Figure 4A4. FIG. 4 is an exploded cross-sectional view of an exemplary embodiment of a composite laminate 430. As shown, particle-embedded surface 420 includes a plurality of particles 422 and resin 424. Resin 424 may be impregnated with particles 422, and particles 422 may be dispersed throughout resin 424. Particles 422 may be mixed into resin 424 prior to application to composite laminate 430 such that the dispersion of particles within resin 424 is random and / or relatively uniform. In this example, the concentration of particles 422 in resin 424 creates sufficient anchoring / bonding points to promote better adhesion of coating 410.

[0080] In some examples, resin 424 can be a thermoplastic-based resin or a thermoset-based resin. In examples where resin 424 is a thermoplastic-based resin, the thermoplastic-based resin can be impregnated with particles 422 during an upstream manufacturing process. In such examples, the particle-impregnated thermoplastic-based resin can be in the form of solid pellets. The solid pellets can be heated until they reach a liquid state, at which point the particle-impregnated thermoplastic-based resin can be suitable for use as particle embedding surface 420. For example, a particle-impregnated thermoplastic-based resin sheet can be formed and subsequently used as particle embedding surface 420. At least one particle-impregnated thermoplastic-based resin sheet can be used as a ply layer, such as a surface ply, during layup of vehicle component 400, such that particle embedding surface 420 can be co-cured with vehicle component 400.

[0081] Prior to coating the particle-embedded surface 420, surface preparation of the composite laminate 430 may be performed to increase adhesion and bonding strength of the particle-embedded surface 420. For example, the surface of the composite laminate 430 may be lightly abraded, such as by sandblasting or emery cloth, to increase adhesion points. The particle-impregnated resin may then be applied, for example, as a surface film, to the surface of the existing composite laminate 430 of the vehicle component 400. The particle-embedded surface 420 may then be cured onto the composite laminate 430, and once cured, the coating 410 may be applied.

[0082] Alternatively, after the particle embedding surface 420 is cured and before the coating 410 is applied, the particle embedding surface 420 may be subjected to surface preparation to increase the adhesion and bonding strength of the coating 410. For example, the cured surface of the particle embedding surface 420 may be ground to increase the surface roughness and the acceptance of the particles 422 by the coating 410.

[0083] In other embodiments, resin 424 can be applied to composite laminate 430 before receiving particles 422, and particles 422 can then be applied to or interspersed along the surface of resin 424 before curing. Particle-embedded surface 420 can then be cured. Subsequently, coating 410 can be applied to particle-embedded surface 420, with or without surface preparation. In such an example, a higher concentration of particles 422 may be present on the surface of particle-embedded surface 420 than on the surface receiving coating 410. This can increase the bond strength and / or adhesion of coating 410 to particle-embedded surface 420 and, therefore, to vehicle component 400.

[0084] In another embodiment, the particle-embedded surface 420 can be created during the manufacture of the composite laminate 430, such as during layup. In this example, particles 422 can be at least partially embedded in selected areas of one or more surface plies during layup and cured onto the composite laminate 430. The particles 422 can also be dispersed along a tool or mold used in the manufacture of the composite laminate 430, so that during layup, the one or more surface plies come into contact with the particles dispersed along the tool and cure onto the surface of the composite laminate 430. The embodiments disclosed in this paragraph allow the particle-embedded surface 420 to be co-cured with one or more surface plies of the composite laminate 430, such that there may be no discernible layer distinction between the two layers. A coating 410 can then be applied to the particle-embedded surface 420 using the methods, techniques, and processes previously discussed with respect to other embodiments. The coating 410 can have the same properties as the coatings 210 and 310 described above.

[0085] refer to Figure 4A 、 Figure 4B and Figure 4C The particles 422 selected for the particle embedding surface 420 may include different materials, sizes, shapes, and structures, which are selected at least in part based on the adhesion / bonding strength capabilities with the coating 410. For example, the particles 422 may include particles similar to the coating 410 to be applied. The particles 422 may include particles similar to the reference coating 410. Figure 2 and Figure 3 The particles disclosed are the same or similar particles.

[0086] Furthermore, the concentration and distribution of particles 422 to resin 424 can vary based at least on the parameters of coating 410 to be applied. For example, particles 422 can include a range of sizes, such as 0-20 μm, 15-45 μm, 40-55 μm, 50-100 μm, 100-150 μm, or ratios between size ranges, to achieve desired D10, D50, and D90 particle size distribution characteristics. Furthermore, the concentration of particles 422 in particle embedding surface 420 can be 0.1-20 weight percent, 20-40 weight percent, 25-50 weight percent, and 30-60 weight percent of the total concentration applied to the rotor surface prior to curing. The dispersion of particles 422 can be substantially uniform across the entire cross-sectional area of ​​particle embedding surface 420, or a higher concentration of particles 422 can be present along the surface of particle embedding surface 420 that receives coating 410. For example, at least 60 weight percent, 70 weight percent, 80 weight percent, or 90 weight percent of the total concentration of particles 422 applied to the rotor surface may be dispersed along the surface or within an appreciable distance from the surface to which coating 410 is applied.

[0087] Resin 424 may be the same as or similar to the matrix used in manufacturing composite laminate 430 to ensure bonding strength of particle embedded surface 420 to composite laminate 430. However, other matrices may be selected depending on the desired properties. The type, properties, and performance of resin 424 may include information about Figure 2 and Figure 3 All aspects of resins and matrices are discussed.

[0088] In some embodiments, the cross-sectional thickness of particle embedding surface 420 may be between 0 and 500 μm. However, in other embodiments, the cross-sectional thickness may be between 500 and 1000 μm, 1000 and 1500 μm, 1500 and 2000 μm, or greater than 2000 μm. As previously described in other embodiments, the cross-sectional thickness may vary along the cross-section of vehicle component 400. For example, in a cross-section of a rotor blade, particle embedding surface 420 may have a thicker cross-sectional thickness along the leading edge and may have no cross-sectional thickness along the trailing edge, indicating that particle embedding surface 420 does not coat the entire surface area of ​​the rotor blade.

[0089] Various embodiments of the coated fiber layer 220, particle-impregnated prepreg layer 320, and particle-embedded surface 420 can increase the adhesion and bonding strength of the coatings 210, 310, and 410, respectively, by increasing the number of attachment points where the particles of the coatings 210, 310, and 410 can anchor during coating. Particles or materials identical or similar to those in the coatings included in the coated fiber layer 220, particle-impregnated prepreg layer 320, and particle-embedded surface 420 can form similar structures for the molten material of the coating to attach to. Similar properties between the particles and / or materials can act like seed particles or seed crystals, allowing the molten material forming the coating to attach and solidify, thereby allowing more molten particles to attach to these anchor points and form a layer. Having thousands of seed particles can create thousands of attachment points for the molten material forming the coating to bond to. As the molten material continues to be applied, the layer can grow along the surfaces of the coated fiber layer 220, particle-impregnated prepreg layer 320, and particle-embedded surface 420, forming a strong, interconnected network of coating material bonded to the particles of the embodiments. Continued application of molten material allows the base layer to grow until the desired surface is fully coated and the optimum coating thickness is achieved.

[0090] Without such anchoring points, the coating may not bond properly due to the different material properties, and as a result, the coating may fail prematurely. Alternatively, in order to form such anchoring points without the coated fiber layer 220, the particle-impregnated prepreg layer 320, and the particle-embedded surface 420, the coating may be forced to be applied at higher energy levels, higher temperatures, and higher speeds, which may damage the structural properties of the material.

[0091] Thermoplastic and / or thermosetting matrices can be used Figures 2 to 4C . For example, thermoplastic and / or thermosetting matrices may be used as the matrix for layers 220, 320, and / or 420. In some examples, the thermoplastic matrix may be a thermoplastic film. The thermoplastic film may take the form of a sheet of thermoplastic material. In some examples, the thermoplastic film may be mated to a surface of a prepreg (such as an outer surface of a thermoplastic prepreg), while in other examples, the thermoplastic film may be mated to a fiber cloth. Heat and / or pressure (e.g., hot pressing) may be applied to the thermoplastic film to increase the plasticity of the resin and promote coupling between the film and the prepreg or fiber cloth. For example, the thermoplastic film may be hot pressed to the VeeloVEIL TM In other examples, multiple thermoplastic films can be used. For example, a prepreg or fiber cloth can be placed between two or more layers of thermoplastic film, and then heat pressed to couple the parts together.

[0092] The thermoplastic film can be impregnated with the aforementioned particles such that the particles are randomly and / or evenly distributed throughout the thermoplastic film. However, in other examples, the particles can be applied to the surface of the thermoplastic film such that upon curing (e.g., application of heat and / or pressure), the particles can become integrated with the thermoplastic film.

[0093] Particle-impregnated thermoplastic plies can allow for integration into vehicle components during the manufacturing process. For example, at least one particle-impregnated thermoplastic laminate ply can be used as a ply during layup of a vehicle component. The entire ply stack can be cured together (e.g., co-cured), which can reduce the likelihood that structural properties will be adversely affected.

[0094] refer to Figures 1 to 4C One or more of the examples described may be combined with one another. For example, a vehicle component based on a thermoplastic matrix may include a particle layer based on a thermosetting material. In such an example, the thermosetting matrix and / or fibers disposed within the thermosetting matrix (e.g., cloth or prepreg plies) may be impregnated and / or coated with particles. In some examples, the thermosetting matrix vehicle component may be cured in a first step, and the particle layer based on a thermosetting material may be coupled to the vehicle component in a second step. For example, the rotor blade 100 ( Figure 1 ) can be made of a thermoplastic laminate followed by a thermosetting material as the resin 424 with the particle embedding surface 420 ( Figure 4A ) coupling. The thermoplastic matrix can provide the desired structural and / or manufacturing properties for the rotor blade 100, while the thermoset matrix can provide the desired particle dispersion properties as a seed layer for particle deposition. Thus, aspects of the first example can be combined with aspects of the other example to achieve optimization of vehicle components.

[0095] Figure 5 is a block diagram illustrating a method 500 for bonding a coating to a composite laminate structure according to an exemplary embodiment of the present invention. Method 500 may include one or more operations or actions, as shown in one or more steps 502-508. Although these steps are shown sequentially, in some cases, these steps may be performed in parallel and / or in a different order than described herein. Furthermore, various blocks may be combined into fewer steps, separated into additional steps, and / or deleted, depending on the desired implementation.

[0096] As shown, method 500 may include preparing a substrate for bonding to an uncured composite laminate at step 502. The substrate may include a resin material and a plurality of particles, wherein the plurality of particles form anchor points for coating deposition.

[0097] At step 504 , method 500 may include co-curing the substrate and the composite laminate such that the substrate is disposed on a portion of an outer surface of the composite laminate.

[0098] At step 506 , method 500 may include determining, for the coating, at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating.

[0099] At step 508 , method 500 may include depositing a coating onto the surface of the substrate using thermal spraying such that the at least one deposited material couples with the at least one particulate material of the substrate.

[0100] In some examples, preparing the substrate for incorporation into the uncured composite laminate may further include determining an amount and type of at least one of a resin material, a fiber material, and at least one particulate material. In these examples, when determining the resin material, the determination is based on material properties of the resin material used in the composite laminate; and when determining the at least one particulate material, the determination is based on bonding properties of the at least one particulate material with at least one deposition material for the coating layer.

[0101] In some examples, preparing a substrate for bonding to an uncured composite laminate may further include: randomly distributing a plurality of particles throughout a resin to form a particle-impregnated resin; impregnating a fiber material with the particle-impregnated resin to form a particle-impregnated ply; and bonding a surface of the particle-impregnated ply to a surface of the uncured composite laminate.

[0102] In some examples, the substrate further comprises a plurality of fibers. The fibers are coated with a plurality of particles to form particle-coated fibers. In such examples, the particle-coated fibers are impregnated with a resin material.

[0103] In some examples, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are coated onto the fibers.

[0104] In some examples, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are randomly distributed throughout the resin.

[0105] In some examples, the composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate may include thermally spraying the coating between 0% and 25% of the chord length from a leading edge of the rotor blade.

[0106] Figure 66 is a block diagram illustrating another method 600 for bonding a coating to a composite laminate structure according to an exemplary embodiment of the present invention. Method 600 may include one or more operations or actions, as shown in one or more steps 602-610. Although these steps are shown in sequence, in some cases, these steps may be performed in parallel and / or in a different order than described herein. In addition, various blocks may be combined into fewer steps, separated into additional steps, and / or deleted depending on the desired implementation.

[0107] As shown, method 600 may include preparing a substrate for bonding to a cured composite laminate at step 602. The substrate may include a resin material and a plurality of particles, wherein the plurality of particles form anchor points for coating deposition.

[0108] At step 604 , method 600 may include applying the prepared substrate to an outer surface of the cured composite laminate.

[0109] At step 606 , method 600 may include curing the prepared base plate onto the outer surface of the cured composite laminate.

[0110] At step 608 , method 600 may include determining, for the coating, at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating.

[0111] At step 610 , method 600 may include depositing a coating onto a surface of a substrate using thermal spraying such that at least one deposited material couples with at least one particulate material of the substrate.

[0112] In some examples, preparing the substrate for incorporation into the cured composite laminate may further include determining an amount and type of at least one of a resin material, a fiber material, and at least one particulate material. In these examples, when determining the at least one particulate material, the determination is based on the binding properties of the at least one particulate material with the at least one deposition material for the coating layer.

[0113] In some examples, preparing a substrate for bonding to a cured composite laminate may further include: randomly distributing a plurality of particles throughout a resin to form a particle-impregnated resin; impregnating a fiber material with the particle-impregnated resin to form a particle-impregnated ply; and bonding a surface of the particle-impregnated ply to a surface of the cured composite laminate.

[0114] In some examples, the substrate may further include a plurality of fibers coated with a plurality of particles to form particle-coated fibers. In such examples, the particle-coated fibers may be impregnated with a resin material.

[0115] In some examples, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are coated onto the fibers.

[0116] In some examples, the substrate is a particle-impregnated prepreg fiber sheet in which a plurality of particles are randomly distributed throughout the resin.

[0117] In some examples, the composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate may include thermally spraying the coating between 0% and 25% of the chord length from a leading edge of the rotor blade.

[0118] The above detailed description describes various features and functions of the disclosed systems, devices, and methods with reference to the accompanying drawings. In the drawings, similar symbols generally represent similar components, unless context dictates otherwise.

[0119] The example embodiments described herein and in the accompanying drawings are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the scope of the subject matter presented herein. It will be readily understood that the various aspects of the present disclosure, as generally described herein and illustrated in the accompanying drawings, may be arranged, substituted, combined, separated, and designed in a variety of different configurations, all of which are expressly contemplated herein.

Claims

1. A vehicle component, comprising: Composite laminates; a base plate coupled to an outer surface of the composite laminate; as well as a coating layer thermally applied to the substrate; The substrate promotes bonding between the thermal coating and the substrate.

2. The vehicle component according to claim 1, wherein: The substrate is a composite material comprising: a plurality of particles comprising at least one particulate material, wherein the plurality of particles promotes bonding between the thermally coated coating and the substrate; Resins; and Fibers impregnated with the resin.

3. The vehicle component according to claim 2, wherein: The fibers of the substrate are coated with the plurality of particles.

4. A vehicle component according to claim 2 or 3, wherein: The plurality of particles are disposed within the resin of the substrate.

5. The vehicle component according to claims 2 to 4, wherein: The resin-impregnated fibers are first fibers, and the composite laminate includes second fibers different from the first fibers.

6. The vehicle component of claim 1, wherein: The substrate comprises: Resins; and A plurality of particles comprises at least one particulate material, wherein the plurality of particles promotes bonding between the thermally coated coating and the substrate.

7. The vehicle component according to claim 6, wherein: The plurality of particles are randomly distributed throughout the resin.

8. The vehicle component according to claim 6, wherein: At least 50% of the plurality of particles are disposed on a surface of the substrate including the thermally-coated coating.

9. A vehicle component according to any one of claims 2 to 8, wherein: The resin is a thermoplastic resin.

10. A vehicle component according to any one of claims 2 to 8, wherein: The resin is a thermosetting resin.

11. A vehicle component according to any one of claims 2 to 10, wherein: The type of resin used in the composite laminate is the same as the resin of the substrate.

12. A vehicle component according to any one of claims 2 to 11, wherein: The substrate is co-cured with the composite laminate and forms an outer layer along a portion of the composite laminate.

13. A vehicle component according to any one of claims 2 to 12, wherein: The plurality of particles includes a first particulate material and a second particulate material different from the first particulate material.

14. A vehicle component according to any one of claims 2 to 13, wherein: The particle material of the coating is the same as the at least one particle material of the plurality of particles of the substrate.

15. A vehicle component according to any one of claims 2 to 12, wherein: The coating is thermally coupled to at least one particle of the plurality of particles of the substrate.

16. A vehicle component according to any one of claims 1 to 13, wherein: The vehicle component is a rotor blade.

17. The vehicle component of claim 16, wherein: The coating is thermally applied between 0% and 25% chord length from the leading edge of the rotor blade.

18. A method of bonding a coating to a composite laminate structure, the method comprising: preparing a substrate for bonding to an uncured composite laminate, the substrate comprising a resin material and a plurality of particles, wherein the plurality of particles form anchor points for deposition of a coating; co-curing the substrate and the composite laminate such that the substrate is disposed on a portion of an outer surface of the composite laminate; determining, for a coating, at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating; and The coating is deposited onto the surface of the substrate using thermal spraying such that the at least one deposited material couples with the at least one particulate material of the substrate.

19. The method according to claim 18, wherein Preparing the substrate for bonding to the uncured composite laminate further comprises: determining an amount and type of at least one of the resin material, the fiber material, and the at least one particulate material, wherein, when determining the resin material, the determination is based on the material properties of the resin material used in the composite laminate; and wherein, when determining the at least one particulate material, the determination is based on the bonding properties of the at least one particulate material with the at least one deposition material used for the coating.

20. The method according to claim 18 or 19, wherein Preparing the substrate for bonding to the uncured composite laminate further comprises: randomly distributing the plurality of particles throughout the resin to form a particle-impregnated resin; impregnating the fibrous material with the particle impregnating resin to form a particle impregnated ply; and The surface of the particle-impregnated ply is joined to a surface of the uncured composite laminate.

21. The method according to claim 18, wherein The substrate also includes a plurality of fibers coated with the plurality of particles to form particle-coated fibers.

22. The method according to claim 21, wherein The particle-coated fibers are impregnated with the resin material.

23. The method according to claim 18, wherein The substrate is a particle-impregnated prepreg fiber sheet, wherein the plurality of particles are coated onto the fibers.

24. The method according to claim 18, wherein The substrate is a particle-impregnated prepreg fiber sheet wherein the plurality of particles are randomly distributed throughout the resin.

25. The method according to any one of claims 18 to 24, wherein The composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate comprises: The coating is thermally sprayed between 0% and 25% of the chord length from the leading edge of the rotor blade.

26. A method of bonding a coating to a composite laminate structure, the method comprising: preparing a substrate for bonding to the cured composite laminate, the substrate comprising a resin material and a plurality of particles, wherein the plurality of particles form anchor points for deposition of a coating; curing the prepared substrate onto the outer surface of the cured composite laminate; curing the prepared substrate onto the outer surface of the cured composite laminate; determining, for a coating, at least one of a deposition type, a deposition temperature, a deposition rate, and at least one deposition material for the coating; and The coating is deposited onto the surface of the substrate using thermal spraying such that the at least one deposited material couples with the at least one particulate material of the substrate.

27. The method according to claim 26, wherein Preparing the substrate for bonding to the cured composite laminate further comprises: determining an amount and type of at least one of the resin material, the fiber material, and the at least one particulate material, Wherein, when determining the at least one particulate material, the determination is based on the combining properties of the at least one particulate material with the at least one deposition material for the coating.

28. The method according to claim 26 or 27, wherein Preparing the substrate for bonding to the cured composite laminate further comprises: randomly distributing the plurality of particles throughout the resin to form a particle-impregnated resin; impregnating the fibrous material with the particle impregnating resin to form a particle impregnated ply; and The surface of the particle-impregnated ply is joined to a surface of the cured composite laminate.

29. The method according to claim 26, wherein The substrate also includes a plurality of fibers coated with the plurality of particles to form particle-coated fibers.

30. The method according to claim 29, wherein The particle-coated fibers are impregnated with the resin material.

31. The method of claim 26, wherein: The substrate is a particle-impregnated prepreg fiber sheet, wherein the plurality of particles are coated onto the fibers.

32. The method of claim 26, wherein: The substrate is a particle-impregnated prepreg fiber sheet wherein the plurality of particles are randomly distributed throughout the resin.

33. The method according to any one of claims 26 to 32, wherein The composite laminate structure is a rotor blade, and depositing the coating onto the surface of the substrate comprises: The coating is thermally sprayed between 0% and 25% of the chord length from the leading edge of the rotor blade.

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